Tubular garment

ABSTRACT

Methods of manufacturing a tubular garment using a knitting machine having a first knitting bed and a second knitting bed are disclosed. An embodiment of the method includes knitting a first fabric panel in the first knitting bed and knitting a second fabric panel in the second knitting bed. The first fabric panel and the second fabric panel being joined to define a first tubular portion of the tubular garment. The method includes temporarily transferring the first fabric panel from the first knitting bed to the second knitting bed and knitting a third fabric panel in the first knitting bed. The method includes joining the third fabric panel to the first fabric panel to define a second tubular portion of the tubular garment. The method includes disposing an electrically conductive bus through the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims all benefit, including priority of U.S. Provisional Patent Application No. 63/108,132, filed Oct. 30, 2020, the entire contents of which are incorporated herein by this reference.

TECHNICAL FIELD

The disclosure relates generally to wearable electronics, and more specifically to smart textiles.

BACKGROUND

Smart textiles are materials that sense and/or react to environmental conditions or stimuli, such as those from mechanical, thermal, chemical, electrical, magnetic or other sources. There is a need for improved ways for forming smart textiles into wearable garments of different types and configurations.

SUMMARY

In an aspect, there is provided a method of manufacturing a tubular garment using a knitting machine that includes a first knitting bed and a second knitted bed. The method includes: knitting a first fabric panel using a first subset of knitting needles of the first knitting bed and knitting a second fabric panel using a first subset of needles of the second knitting bed, the first fabric panel and the second fabric panel being joined to define a first tubular portion of the tubular garment; transferring the first fabric panel from the first knitting bed to the second knitting bed, the first fabric panel thereupon being held by a second subset of needles of the second knitting bed; knitting a third fabric panel on the first knitting bed using a second subset of needles of the first knitting bed; joining the third fabric panel to the first fabric panel to define a second tubular portion of the tubular garment; disposing an electrically conductive bus in the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.

In another aspect, there is provided a first fabric panel; a second fabric panel that is adjoined to the first fabric panel, the second fabric panel being formed integrally with the first fabric panel to define a first tubular portion of the tubular garment; a third fabric panel that is adjoined to the first fabric panel on a surface of the first fabric panel, the third fabric panel and the first fabric panel defining a second tubular portion, wherein a conductive bus is disposed within the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.

Further details of these and other aspects of the subject matter of this application will be apparent from the detailed description included below and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying drawings, in which:

FIG. 1 is a schematic diagram of a system used for manufacturing a tubular garment, in accordance with an embodiment;

FIGS. 2A-2D are a top view, front perspective view, side view and front view, respectively, of a tubular garment, in accordance with an embodiment;

FIG. 3 is a cross-sectional view of a first fabric panel of a tubular garment having conductive yarn inlaid within the first fabric panel, in accordance with an embodiment;

FIGS. 4A-4C are a front perspective view, a rear elevation view, and a rear perspective view, respectively, of a tubular garment having a plurality of electronic components integrated within a tubular portion of the tubular garment, in accordance with an embodiment;

FIG. 5 is a flowchart illustrating an example method for manufacturing a tubular garment, in accordance with an embodiment;

FIG. 6A is a perspective view of a configuration of a knitting machine when knitting a first fabric panel and a second fabric panel of a tubular garment, in accordance with an embodiment;

FIG. 6B is a perspective view of a configuration of a knitting machine after the first fabric panel of FIG. 5A is temporarily transferred from a first knitting bed to a second knitting bed and during knitting of a third fabric panel of a tubular garment, in accordance with an embodiment;

FIG. 6C is a perspective view of a configuration of knitting machine after the first fabric panel of FIG. 5B is transferred back to a first knitting bed and after the third fabric panel of FIG. 5B is knitted, in accordance with an embodiment; and

FIG. 7 is a perspective view of a tubular garment, in accordance with an embodiment.

DETAILED DESCRIPTION

The following description discloses tubular garments and methods useful for manufacturing a tubular garment.

In some embodiments, a tubular garment disclosed herein include a first tubular portion defined by a first fabric panel and a second fabric panel and a second tubular portion defined by the first fabric panel and a third fabric panel. A conductive bus including one or more electrically conductive wires may be disposed within the second tubular portion between the first fabric panel and the third fabric panel. The conductive bus may be electrically coupled to at least one electrically conductive yarn integrated within the tubular garment.

In some embodiments, the methods disclosed herein for manufacturing the tubular garment may include knitting the first fabric panel in a first knitting bed of a knitting machine and knitting the second fabric panel in a second knitting bed of the knitting machine. In some embodiments, the methods disclosed herein may include temporarily transferring the first fabric panel from the first knitting bed to the second knitting bed to allow the third fabric panel to be knitted in the first knitting bed.

Aspects of various embodiments are described through reference to the

drawings.

FIG. 1 is a schematic diagram of a system 10 for manufacturing tubular garment 22 (as shown in FIG. 2A-2D). System 10 may include controller 14 and one or more user input devices 12 (referred hereinafter in the singular). Controller 14 may be configured to receive input from user input device 12 via one or more communication terminals/ports.

Controller 14 may include one or more data processors 20 (referred hereinafter in the singular) and one or more computer-readable memories 16 (referred hereinafter in the singular) storing machine-readable instructions 18 executable by data processor 20 and configured to cause data processor 20 to generate one or more outputs (e.g., signals) for causing the execution of one or more steps of the methods described herein.

Data processor 20 may include any suitable device(s) configured to cause a series of steps to be performed by controller 14 so as to implement a computer-implemented process such that instructions 18, when executed by controller 14 or other programmable apparatus, may cause the functions/actions specified in the methods described herein to be executed. Data processor 20 may include, for example, any type of general-purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an integrated circuit, a field programmable gate array (FPGA), a reconfigurable processor, other suitably programmed or programmable logic circuits, or any combination thereof.

Memory 16 may include any suitable machine-readable storage medium. Memory 16 may include non-transitory computer readable storage medium such as, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. Memory 16 may include a suitable combination of any type of computer memory that is located either internally or externally to controller 14. Memory 16 may include any storage means (e.g. devices) suitable for retrievably storing machine-readable instructions 18 executable by data processor 20.

User input device 12 may be an electronic device having a graphical user interface (GUI) such as a desktop computer, laptop computer or a mobile device such as a tablet for example. User input device 12 may be configured to receive user inputs from an operator. The user inputs may include computer-readable instructions related to a desired knitting pattern for a textile article.

The computer-readable instructions may include manufacturing instructions for controlling the operation of a knitting machine to construct tubular garment 22.

Tubular garment 22 may be formed of one or more fabric panels 24A-24C (as shown in FIGS. 2A-2D) (hereinafter collectively referred to as “fabric panels 24”) composed yarn. This yarn includes non-conductive yarn, and as detailed below, may also include conductive yarn. The non-conductive yarn can include any textile material such as cotton, spandex, nylon, polyester, and/or various synthetic materials. The computer-readable instructions may indicate an arrangement of the non-conductive yarn in fabric panels 24. In some embodiments, conductive yarn may be inlaid within one or more fabric panels 24 to provide conductive paths.

The computer-readable instructions may indicate the material of the non-conductive yarn and the material of the conductive yarn used to manufacture tubular garment 22. The computer-readable instructions may indicate one or more locations where a conductive path electrically couples a conductive bus that is not inlaid within the one or more fabric panels. In some embodiments, the locations may be on a surface of one of the fabric panels.

Controller 14 may be configured to process the computer-readable instructions to determine a set of operating parameters for one or more machines. Controller 14 may be further configured to generate a plurality of signals indicative of the determined operating parameters for the one or more machines. Controller 14 may be configured to transmit each signal of the plurality of signals to a respective machine of the one or more machines via the one or more communication terminals/ports. The one or more machines may include knitting machine 21.

In some embodiments, system 10 may include a suitable combination for machines for forming electrical connections in tubular garment 22, e.g., between any combination of electrically conductive yarns, a conductive bus, conductive wires, and electronic components of tubular garment 22. Such machines may include, for example, a soldering machine and/or a welding machine, embodiments of which are described, for example, in PCT Patent Application No. WO2021/119828, entitled “METHOD OF MANUFACTURING TEXTILES WITH INTEGRATED ELECTRICAL PATHS AND ELECTRONICS” (hereinafter referred to as the '828 patent application), the entire contents of which are herein incorporated by reference.

In some embodiments, system 10 may include one or more sewing machines, e.g., for sewing on trim or other features of tubular garment 22.

In some embodiments, system 10 may include machines for implementing wet processing of tubular garment 22, including washing and drying machines.

Knitting machine 21 may be a computerized flat bed knitting machine. Knitting machine 21 may include first knitting bed 80A and second knitting bed (hereinafter referred to as “knitting beds 80”, as shown in FIGS. 6A-6C). Knitting machine 21 may include a cam system for independently controlling a position of one or more knitting needle in a knitting bed 80. Each knitting needle may be positioned to be in a non-working position or a working position. Needles in a non-working position may not move or knit when a carriage of knitting machine 21 is moved. In some embodiments, knitting machine 21 is a flat bed knitting machine that has a v-shaped bed configuration and may be referred to as a v-bed knitting machine.

In some embodiments, knitting machine 21 could be a suitable machine manufactured by Stoll, Shima Siekie or any other suitable flat bed knitting machine that allow for the transfer and temporary holding of a fabric panel on needles not being used for knitting.

Knitting machine 21 may be configured to receive one or more signals indicative of operating parameters for knitting machine 21 from controller 14. Knitting machine 21 may include a separate controller having one or more data processors and one or more computer-readable memories storing machine-readable instructions executable by the one or more data processors (not depicted). In some embodiments, the one or more signals from controller 14 may be received by the controller of knitting machine 21. In response to receiving the one or more signals, knitting machine 21 may be configured to operate under the defined operating parameters set out in the one or more signals received. When operating under these operating parameters, knitting machine 21 may be configured to form tubular garment 22 by knitting non-conductive yarn and/or conductive yarn in accordance with the desired knitting pattern received from user input device 12.

In some embodiments, controller 14 may be part of knitting machine 21 and the operation of knitting machine 21 may be directly controlled by such an integrated controller 14.

FIGS. 2A-2D show a top view, front perspective view, side view and front view, respectively, of tubular garment 22. Tubular garment 22 may include first fabric panel 24A, second fabric panel 24B, and third fabric panel 24C. Each fabric panel 24 may include one or more non-conductive layers. In some embodiments, first fabric panel 24A and second fabric panel 24B may be integrally formed to define first tubular portion 26. First tubular portion 26 may define an opening between first fabric panel 24A and second fabric panel 24B for receiving a limb (or other body portion) of a wearer of tubular garment 22. In use, a portion of the limb of the wearer may be covered by first fabric panel 24A and second fabric panel 24B. In some embodiments, tubular garment 22 may be a wearable sock having first tubular portion 26 sized to fit a foot of a wearer of tubular garment 22. In a situation where tubular garment 22 is a sock, first tubular portion 26 may have an open end and a closed end (not depicted). In use, the closed end may be positioned in the region of the wearer's toes and the open end may be positioned between the wearer's calf muscle and the wearer's knee.

Although tubular garment 22 is depicted as being a sock in FIGS. 2B and 2D, it should be understood that in alternate embodiments, tubular garment 28 may be a knee brace, elbow sleeve, multiclava, neck warmer, stocking, legging, or the like.

Third fabric panel 24C may be joined to first fabric panel 24A on surface of first fabric panel 24A. As depicted, surface 30 of first fabric panel 24A faces away from second fabric panel 24B. First fabric panel 24A and third fabric panel 24C may define a second tubular portion 40 of tubular garment 22. Second tubular portion 40 may be a close-ended tube defining cavity 32 between first fabric panel 24A and third fabric panel 24C. As depicted in FIGS. 2B and 2D, cavity 32 may include narrow portion 32A and wide portion 32B. Third fabric panel 24C may be stitched to first fabric panel 24A along a perimeter of third fabric panel 24C. Tubular garment 22 may also have one or more additional stitches 31 between a lower portion of third fabric panel 24C that defines wide portion 32B of cavity 32 and first fabric panel 24A. Stitches 31 between the lower portion of third fabric panel 24C and first fabric panel 24A cause the lower portion of third fabric panel 24C to be closely pressed up against surface 30 of first fabric panel 24A. The one or more additional stitches 31 may extend horizontally across tubular garment 22. Such stitches 31 may also serve to divide wide portion of cavity 32 into a plurality of horizontal regions. As shown in FIG. 2B, additional stitches 31 may be used to join first fabric panel 24A and second fabric panel 24B. As shown in FIG. 2C, additional stitches 31 may be used to join first fabric panel 24A and third fabric panel 24C.

As depicted in FIG. 2B, tubular garment 22 may include conductive bus 28 disposed within second tubular portion 40 to provide electrical communication with at least one conductive yarn 34 integrated in tubular garment 22. Conductive bus 28 may include one or more conductive wires that are electrically coupled to power source 38 (e.g., a battery). Conductive bus 28 may be disposed within narrow portion 32A of cavity 32 and may be electrically coupled to conductive yarn 34 at locations 36A and 36B. Conductive bus 28 may be easily accessible in cavity 32 by a person. Power source 28 may be external to tubular garment 22 or may be disposed within cavity 32. Power source 28 may be easily accessible by a person allowing quick replacement of power source 28 if required. Conductive yarn 34 may be made of any conductive material including conductive metals such as stainless steel, silver, aluminium, copper, etc. As depicted in FIG. 2B, first conductive wire 28A of conductive bus 28 may connect conductive yarn 34 to a positive terminal of power source 38, and a second conductive wire 28B may connect conductive yarn 23 to a negative terminal of power source 38.

In some situations, as depicted in FIGS. 2B-2C, conductive yarn 34 may be disposed within cavity 32 between first fabric panel 24A and third fabric panel 24C. In these situations, conductive yarn 34 may be disposed within wide portion 32B of cavity 32 and locations 36A and 36B may be at an interface between narrow portion 32A and wide portion 32B of cavity 32. In some embodiments, conductive yarn 34 may be soldered or ultrasonically welded to first conductive wire 28A and second conductive wire 28B at locations 36A and 36B, respectively, in order to provide said electrical coupling. In some embodiments, the methods of forming an electrical connection between conductive yarn 34 and conductive bus 28 are similar to the methods described in the '828 patent application.

Conveniently, disposing at least part of conductive bus 28 and/or at least part of conductive yarn 34 within cavity 32 inhibits contact of such parts with skin of a wearer of tubular garment 22. This may improve comfort and/or safety of wearer. This may also improve durability tubular garment 22, e.g., by reducing wear caused by contact of such parts with the wearer.

In some situations, conductive yarn 34 may be inter-knit with non-conductive yarns of tubular garment 22. FIG. 3 shows a cross-sectional view of first fabric panel 24A having conductive yarn 34 inlaid within first fabric panel 24A. As depicted in FIG. 3 , at least a portion of conductive yarn 34 may be disposed between non-conductive yarns of first fabric panel 24. At least a portion of conductive yarn 34 may be inlaid within first fabric panel 24A such that conductive yarn 34 is at sufficient distance from surface 42 of first fabric panel 24. Surface 42 of first fabric panel is opposite surface 30 and may be in contact with a limb of a wearer when tubular garment 22 is worn by the wearer. Conductive yarn 34 being disposed at a sufficient distance from surface 42 may provide thermal and/or electrical protection for the wearer. In some embodiments, a substantial portion of conductive yarn 34 may be disposed in a middle section of first fabric panel 24A. Conductive yarn 34 may extend from the middle section to surface 30 of first fabric panel 24A to be electrically coupled to conductive bus 28 at locations 36A and 36B. In some embodiments, the conductive yarn 34 may be soldered or ultrasonically welded to conductive bus 28 in order to provide said electrical coupling.

In some embodiments, at least a portion of conductive yarn 34 is inlaid within second fabric panel 24B. In some embodiments, at least a portion of conductive yarn 34 is inlaid within third fabric portion 24C. In some embodiments, conductive yarn 34 may be knitted on a surface of one of fabric panels 24A, 24B, 24C that faces an internal cavity of tubular garment 22 such as, for example, cavity 32 or a cavity formed between first fabric panel 24A and second fabric panel 24B. In some embodiments, conductive yarn 34 may be knitted between transfer points 90 to ensure accurate positioning.

In some embodiments, conductive yarn 34 may be arranged in textile garment 22 to provide resistive heating. Conductive yarn 34 may act as an electrically resistance element and a voltage may be supplied by power source 38 to conductive yarn 24. The temperature of conductive yarn 34 may be increased due to the thermal coefficient of resistance of conductive yarn 24.

Although FIG. 2B shows tubular garment 22 having one conductive yarn 34, it should be understood that tubular garment 22 may have a plurality of conductive yarns defining a plurality of conductive paths. It should be understood that conductive yarns 34 may be integrated in any one of the panels 24. It should be understood that the conductive bus 28 disposed in second tubular portion 40 may be configured to provide electrical communication with conductive yarns 34 integrated in any one of the panels 24.

In some embodiments, tubular garment 22 may include one or more electronic components. Tubular garment 22 may be used to detect and monitor a wide range of health issues, including: tracking of gait, pressure sensing, electromyography (EMG), heat stimulation and electrical muscle stimulation (EMS).

FIGS. 4A-4C show different perspective views of an embodiment of tubular garment 22 having a plurality of electronic components 46, 48, 56, 58 integrated within first tubular portion 26 of tubular garment 22. Electronic components 46, 48, 56, 58 may be embedded within first fabric panel 24A and/or second fabric panel 24B and may be electrically coupled to conductive bus 28 via a plurality of conductive yarns 34 (not depicted). Electronic components 46, 48, 56, 58 may also be in communication with controller 60 via conductive yarns 34. Controller 60 may be configured to receive signals from electronic components 46, 48, 56, 58. Controller 60 may be configured to control the operation of one or more of the electronic components 46, 48, 56, 58 based on the received signals.

Referring to FIG. 4A, tubular garment 22 (shown by example only as a sock) may have inertial measurement unit (IMU) sensor 46 connected to body 49 of first tubular portion 26 that measures and reports a body's (e.g. limb of the wearer) specific force, angular rate, and/or sometimes the magnetic field surrounding the body, using a combination of accelerometers and gyroscopes, sometimes also magnetometers. Body 49 may refer to the portion of first tubular portion 26 consisting of non-conductive interlaced yarns. Example configurations of IMU sensor 46 can be used to detect linear acceleration of the wearer's limb using one or more onboard accelerometers and rotational rate using one or more onboard gyroscopes. Some IMU sensors 46 can also include an onboard magnetometer used as a heading reference. Typical configurations of IMU sensors 46 contain one accelerometer, gyro, and magnetometer per axis for each of the three axes: x, y and z.

Tubular garment 22 may have one or more stretch/strain sensors 48 positioned on/in body 49 and across intermediate region 50 of first tubular portion 26 in order to detect flexure of the wearer's joint underlying intermediate region 50, as the wearer moves the limb during physical activity (e.g. walking, running, lifting, carrying, or otherwise engaging relative movement of the limb with respect to the rest of the wearer's body). Top region 52 and bottom region 54 of first tubular portion 26 may be oriented at an angle to one another about intermediate region 50. For example, stretch/strain sensors 48 may be applied to a surface of body 49 (e.g. consisting of nonconductive interlaced yarns). Alternatively, stretch/strain sensors 48 may be composed of conductive fibers/yarns that are interlaced (e.g. knit or woven) with the non-conductive yarns of body 49.

Tubular garment 22 may also have electromyography (EMG) sensors 56 on/in the body 49 used for evaluating and recording/detecting electrical activity produced by skeletal muscles (e.g. calf muscles, forearm muscles, bicep/tricep muscles, hand muscles, and general foot/leg muscles such as but not limited to dorsiflexor and plantarflexor muscles). EMG sensors 56 can be used to detect/record the electric potential generated by muscle cells when these cells are electrically or neurologically activated (e.g. by the wearer's brain in order to effect movement of the limb). The EMG signals detected by EMG sensors 56 may be analyzed to detect medical abnormalities, activation level, or recruitment order, or to analyze the biomechanics of human or animal movement. For example, EMG sensors 56 may be applied to a surface of body 49 (e.g. consisting of nonconductive interlaced fibres). Alternatively, EMG sensors 56 may be composed of conductive fibers/yarns that are interlaced (e.g. knit or woven) with the nonconductive yarns of body 49.

Tubular garment 22 may also have electrical muscle stimulation (EMS) actuators 58, also known as neuromuscular electrical stimulation (NMES) or electromyostimulation, which is the elicitation of muscle contraction using electric impulses applied by the EMS actuators 58. The impulses can be transmitted to the EMS actuators 58 and delivered through the electrodes (i.e. the EMS actuators 58) on the wearer's skin near to the muscles being stimulated. The EMS actuators 58 may be pads that are positioned or otherwise biased into engagement with the skin. For example, the non-conductive yarns of body 49 can be resilient (e.g. elastic) in nature and thus promote contact of the sensors 56, 58 with the skin of the wearer underlying body 49. As such, the EMS impulses applied by the EMS actuators 58 can mimic the action potential that comes from the central nervous system, causing the underlying muscles to contract and thus promote movement of the underlying skeletal structure of the limb. For example, EMS actuators 58 can be applied to a surface of body 49 (e.g. consisting of nonconductive interlaced yarns). Alternatively, EMS actuators 58 may be composed of conductive yarns that are interlaced (e.g. knit or woven) with the non-conductive yarns of body 49 material. It is recognized that EMS actuators 58 and EMG sensors 59 can be the same, or different, electronic components connected to controller 60 via conductive yarns 34.

The electrically conductive fibers/yarn incorporated into tubular garment 22 as one or more electronic components 46, 48, 56, 58 can be made of any conductive material including conductive metals such as stainless steel, silver, aluminium, copper, etc. In one embodiment, the conductive yarn can be insulated. In another embodiment, the conductive yarn can be uninsulated.

Other examples of electronic components that may be incorporated into tubular garment 22 are disclosed in International Patent Publication No. WO2019134033A2, entitled “MULTI-FUNCTIONAL TUBULAR WORN GARMENT”, the entire contents of which are herein incorporated by reference.

FIG. 5 is a flowchart illustrating an example method 62 for manufacturing tubular garment 22 in accordance with an embodiment. Method 62 can be performed using system 10 described herein or using another system. It is understood that aspects of method 62 can be combined with aspects of other methods described herein. In various embodiments, method 62 includes:

knitting a first fabric panel using a first subset of knitting needles of a first knitting bed and knitting a second fabric panel using a first subset of needles of a second knitting bed, the first fabric panel and the second fabric panel being joined to define a first tubular portion of the tubular garment (block 64);

transferring the first fabric panel from the first knitting bed to the second knitting bed, the first fabric panel thereupon being held by a second subset of needles of the second knitting bed (block 66); and

knitting a third fabric panel on the first knitting bed using a second subset of needles of the first knitting bed (block 68);

joining the third fabric panel to the first fabric panel to define a second tubular portion of the tubular garment (block 70); and disposing an electrically conductive bus through the second tubular

portion for electrical communication with one or more conductive yarns integrated within the tubular garment (block 72).

FIG. 6A shows a perspective view of a configuration of knitting machine 21 when knitting first fabric panel 24A and second fabric panel 24B. As depicted, first fabric panel 24A may be knitted using first subset of knitting needles 82A of first knitting bed 80A and second panel 24B may be knitted using first subset of knitting needles 82B of second knitting bed 80B. Second subset of knitting needles 84A of first knitting bed 80A and second subset of knitting needles 84B of second knitting bed 80B may be in a non-working position during the knitting of first fabric panel 24A and second fabric panel 24B. As depicted, first subset of knitting needles 82A of first knitting bed 80A and second subset of knitting needles 84A of first knitting bed 80A are alternatingly arranged in first knitting bed 80A. Similarly, first subset of knitting needles 82B of second knitting bed and second subset of knitting needles 84B of second knitting bed 80B are alternatingly arranged in second knitting bed 80B. So arranged, on each knitting bed, one subset of knitting needles may be referred to as odd needles and the other subset of knitting needles may be referred to as even needles.

Although it not depicted in FIG. 6A, first fabric panel 24A may be joined to second fabric panel 24B. First fabric panel 24A and second fabric panel 24B may be integrally formed to define first tubular portion 26. In some embodiments, strands of yarn may be passed between first knitting bed 80A and second knitting bed 80B during knitting to integrally form first fabric panel 24A and second fabric panel 24B.

In some embodiments, knitting first fabric panel 24A may include inlaying at least one conductive yarn 34 within first fabric panel 24A such that the at least one conductive yarn 34 is disposed between non-conductive yarns of first fabric panel 24A.

FIG. 6B shows a perspective view of a configuration of knitting machine 21 after first fabric panel 24A is temporarily transferred from first knitting bed to second knitting bed 80B and during knitting of third panel 24C. As depicted, first fabric panel 24A may be held by second subset of needles 84B of second knitting bed 80B when transferred to second knitting bed 80B. Third fabric panel 24C may be knitted using second subset of needles 84A of first knitting bed 80A. First subset of knitting needles 82A of first knitting bed 80A and first subset of knitting needles 82B of second knitting bed 80B may be in a non-working position when knitting third fabric panel 24C. By temporarily transferring fabric panel 24A to second knitting bed 80B, it advantageously allows third fabric panel 24C to be knitted alongside first fabric panel 24A and second fabric panel 24B in a single knitting process. Although it not depicted in FIG. 6B, third fabric panel 24C may be joined to first fabric panel 24A to define second tubular portion 40 during the knitting process. Joining third fabric panel 24C to first fabric panel 24A may include stitching third fabric panel 24C to first fabric panel 24A along a perimeter of third fabric panel 24C. In some embodiments, joining third fabric panel 24C to first fabric panel 24A may include stitching a lower portion of third fabric panel 24C to first fabric panel 24A such that the lower portion of third fabric panel 24C is closely pressed up against surface 30 of first fabric panel 24A.

FIG. 6C shows a perspective view of a configuration of knitting machine 21 after first fabric panel 24A is transferred back to first knitting bed 80A and after at least a portion of third fabric panel 24C has been knitted. As depicted, first fabric panel 24A is held by first subset of knitting needles 82A of first knitting bed 80A after first fabric panel 24A is transferred back to first knitting bed 80A. Second subset of needles 84B of second knitting bed 80B holding third fabric panel 24A may be retracted and may be in a non-working position after first fabric panel 24A is transferred back to first knitting bed 80A. In some embodiments, an extension may be knitted to first fabric panel 24A using first subset of knitting needles 82A of first knitting bed 80A and an extension may be knitted to second fabric panel 24B using first subset of knitting needles 82B of second knitting bed 80B.

During knitting of tubular garment 22, first fabric panel 24A may be transferred back and forth between first knitting bed 80A and second knitting For example, first fabric panel 24A can be transferred back to first knitting bed 80A to place first fabric panel 24A into a knitting position that allow knitting of first fabric panel 24A to resume (on first knitting bed 80A) and knitting of second fabric panel 24B to resume (on second knitting bed 80B). During this time, third fabric panel 24C may be maintained in a holding position at second knitting bed 80B. Subsequently, first fabric panel 24A can be transferred again to the second knitting bed 80A and maintained in a holding position at second knitting bed 80B, thereby freeing first knitting bed 80A to resume knitting third fabric panel 24C while third fabric panel 24C is in this knitting position. In this way, fabric panels are shifted repeatedly between holding positions and knitting positions to build the courses for each of the fabric panels as required, e.g., in accordance with instructions 18.

FIG. 6D shows a perspective view of a configuration of knitting machine 21 for joining first fabric panel 24A and second fabric panel 24B. As depicted, each of first fabric panel 24A and second fabric panel 24B extends from a first end 92 of knitting machine 21 to a second end 94 of knitting machine 21, with portions each of these panels omitted for clarity of depiction.

At each of ends 92 and 94, a pair of needles, namely a needle 82A of first knitting bed 80A and a needle 82B of second knitting bed 80B, cross at a stitch transfer point 90. Each stitch transfer point 90 defines the location where a stich is passed from a needle 82A to a needle 82B, or vice versa, as first fabric panel 24A and second fabric panel 24B are knit. In this way, one or more stitches are shared between first knitting bed 80A and second knitting bed 80B, with the one or more stitches transferred from one knitting bed to the other upon reaching a stitch transfer point. This manner of stitching causes first fabric panel 24A and second fabric panel 24B to be joined as they are knitted, thereby forming tubular portion 26. As will be appreciated, the width of each fabric panel (and hence the width of tubular portion 26) is defined by the number of needles of the corresponding knitting bed which are in a working position between the two stitch transfer points 90.

The configuration of knitting machine 21 described with reference to FIG. 6D may also be used in similar manner for joining first fabric panel 24A and third fabric panel 24C to form second tubular portion 40.

FIG. 7 is a perspective view of tubular garment 22 in accordance with one embodiment before conductive bus 28 is disposed in second tubular portion As depicted, third fabric panel 24C may be stitched to first fabric panel 24A along a perimeter of third fabric panel 24C. However, in this depiction, a lower portion of third fabric panel 24C is not stitched to first fabric panel 24A such that the lower portion of third fabric panel 24C is closely pressed up against surface of first fabric panel 24A.

After first fabric panel 24A is transferred back to first knitting bed 80A and third fabric panel 24C has been knitted, conductive bus 28 may be disposed within second tubular portion 40 to provide electric communication with conductive yarn 34. Establishing an electrical coupling between conductive bus 28 and conductive yarn 34 may involve soldering or welding at an interface between conductive bus 28 and conductive yarn 34.

In a situation where conductive yarn 34 is inlaid within first fabric panel 24A, conductive bus 28 may electrically coupled to conductive yarn 34 at one or more locations 36 on surface 30 of first fabric panel 24A.

In a situation where conductive yarn 34 is not inlaid within first fabric panel 24A, conductive yarn may be disposed within cavity 32 and then electrically coupled to conductive bus 28 which is also disposed within cavity 32.

Heel

A method is provided to form a heel in embodiments of tubular garment 22 having a heel. According to this method, fabric is knit on first knitting bed 80A and second knitting bed 80B with unbalanced courses. For example, fabric on the heel side of tubular garment 22 may be knit with a 3-1, 4-1, 5-1, or other suitable course ratio. The use of such unbalanced course ratios produces greater fabric area (more courses) on the heel side of tubular garment 22, allowing the heel side to bend at the wearer heel or contour around it, while maintaining consistent fabric density with minimal stretching.

Importantly, according to this method, layers of fabric on both sides of tubular garment 22 (e.g., first fabric panel 24A, second fabric panel 24B, and third fabric panel 24C) are passed at the same time between first knitting beds and second knitting beds 80B.

Embodiments of manufacturing systems employing this method may avoid friction that is created when holding fabric on one knitting bed while knitting on the opposite knitting bed, as associated with a conventional Goring method. Conveniently, such embodiments may produce multi-tubular garments with consistent quality of stitch formation.

This method may be applied to various types of tubular construction, including construction of angular bends, curvatures or pocket type zones.

Due to the discrete nature, size and comfort, a tubular shaped garment, such as a sock, knee brace, elbow sleeve, stocking, legging, and the like are especially attractive form factors for a smart textile in particular for applications involving health and wellness and performance sports, where a sock can be used to detect and monitor a wide range of health issues, including: tracking of gait, pressure sensing, electromyography (EMG), heat stimulation and electrical muscle stimulation (EMS) of the calf for improved circulation and bio-impedance feedback for sub-skin infection monitoring and other combined features.

In some embodiments, at least part of tubular garment 22 may be formed of other textile forms and/or techniques such as weaving, knitting (warp, weft, etc.) or the like. In some embodiments, tubular garment 22 includes any one of a knitted textile, a woven textile, a cut and sewn textile, a knitted fabric, a non-knitted fabric, in any combination and/or permutation thereof. Example structures and interlacing techniques of textiles formed by knitting and weaving are disclosed in U.S. patent application Ser. No. 15/267,818, entitled “Conductive Knit Patch”, the entire contents of which are herein incorporated by reference.

As used herein, “textile” refers to any material made or formed by manipulating natural or artificial fibres to interlace to create an organized network of fibres. Generally, textiles are formed using yarn, where yarn refers to a long continuous length of a plurality of fibres that have been interlocked (i.e. fitting into each other, as if twined together, or twisted together). Herein, the terms fibre and yarn are used interchangeably. Fibres or yarns can be manipulated to form a textile according to any method that provides an interlaced organized network of fibres, including but not limited to weaving, knitting, sew and cut, crocheting, knotting and felting.

Different sections of a textile can be integrally formed into a layer to utilize different structural properties of different types of fibres. For example, conductive fibres can be manipulated to form networks of conductive fibres and non-conductive fibres can be manipulated to form networks of non-conductive fibers. These networks of fibres can comprise different sections of a textile by integrating the networks of fibres into a layer of the textile. The networks of conductive fibres can form one or more conductive pathways that electrically connect with actuators and sensors embedded in tubular garment 22, for conveying data and/or power to and/or from these components.

In some embodiments, multiple layers of textile can also be stacked upon each other to provide a multi-layer textile.

As used herein, “interlace” refers to fibres (either artificial or natural) crossing over and/or under one another in an organized fashion, typically alternately over and under one another, in a layer. When interlaced, adjacent fibres touch each other at intersection points (e.g. points where one fibre crosses over or under another fibre). In one example, first fibres extending in a first direction can be interlaced with second fibres extending laterally or transverse to the fibres extending in the first connection. In another example, the second fibres can extend laterally at 90° from the first fibres when interlaced with the first fibres. Interlaced fibres extending in a sheet can be referred to as a network of fibres.

As used herein “integrated” or “integrally” refers to combining, coordinating or otherwise bringing together separate elements so as to provide a harmonious, consistent, interrelated whole. In the context of a textile, a textile can have various sections comprising networks of fibres with different structural properties. For example, a textile can have a section comprising a network of conductive fibres and a section comprising a network of non-conductive fibres. Two or more sections comprising networks of fibres are said to be “integrated” together into a textile (or “integrally formed”) when at least one fibre of one network is interlaced with at least one fibre of the other network such that the two networks form a layer of the textile. Further, when integrated, two sections of a textile can also be described as being substantially inseparable from the textile. Here, “substantially inseparable” refers to the notion that separation of the sections of the textile from each other results in disassembly or destruction of the textile itself.

The above description is meant to be exemplary only, and one skilled in the relevant arts will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The present disclosure is intended to cover and embrace all suitable changes in technology. Modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. Also, the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. 

1. A method of manufacturing a tubular garment using a knitting machine that includes a first knitting bed and a second knitted bed, the method comprising: knitting a first fabric panel using a first subset of knitting needles of the first knitting bed and knitting a second fabric panel using a first subset of needles of the second knitting bed, the first fabric panel and the second fabric panel being joined to define a first tubular portion of the tubular garment; transferring the first fabric panel from the first knitting bed to the second knitting bed, the first fabric panel thereupon being held by a second subset of needles of the second knitting bed; knitting a third fabric panel on the first knitting bed using a second subset of needles of the first knitting bed; joining the third fabric panel to the first fabric panel to define a second tubular portion of the tubular garment; and disposing an electrically conductive bus in the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.
 2. The method of claim 1, wherein: joining the third fabric panel to the first fabric panel forms a pocket between the third fabric panel and the first fabric panel; and disposing the conductive bus in the second tubular portion includes disposing the conductive bus through the pocket.
 3. The method of claim 2, wherein: the at least one conductive yarn is inlaid within the first fabric panel.
 4. The method of claim 2, further comprises: disposing the at least one conductive yarn in the pocket between the third fabric panel and the first fabric panel.
 5. The method of claim 1, further comprises: electrically coupling the conductive bus to the at least one conductive yarn.
 6. The method of claim 1, further comprises: transferring the first fabric panel from the second knitting bed back to the first knitting bed, the first fabric panel thereupon being held by the first subset of knitting needles of the first knitting bed.
 7. The method of claim 6, further comprises: knitting an extension to the first fabric using the first subset of needles of the first knitting bed and knitting an extension to the second fabric panel using the first subset of needles of the second knitting bed.
 8. The method of claim 1, wherein: the second subset of knitting needles of the first knitting bed are in a non-working position when knitting the first fabric panel using the first subset of knitting needles of the first knitting; and the second subset of knitting needles of the second knitting bed are in a non-working position when knitting the second fabric panel using the first subset of knitting needles of the second knitting bed.
 9. The method of claim 1, wherein: the first subset of knitting needles of the first knitting bed and the second subset of knitting needles of the first knitting bed are alternatingly arranged in the first knitting bed; and the first subset of knitting needles of the second knitting bed and the second subset of knitting needles of the second knitting bed are alternatingly arranged in the second knitting bed.
 10. The method of claim 1, wherein: the first fabric panel and the second fabric panel are integrally formed to define the first tubular portion of the tubular garment.
 11. The method of claim 1, wherein the knitting machine is a flat-bed knitting machine.
 12. The method of claim 1, wherein the knitting machine is a V-bed knitting machine.
 13. A tubular garment comprising: a first fabric panel; a second fabric panel that is adjoined to the first fabric panel, the second fabric panel being formed integrally with the first fabric panel to define a first tubular portion of the tubular garment; a third fabric panel that is adjoined to the first fabric panel on a surface of the first fabric panel, the third fabric panel and the first fabric panel defining a second tubular portion, wherein a conductive bus is disposed within the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.
 14. The tubular garment of claim 13, wherein the second tubular portion includes a cavity between the first fabric panel and the third fabric panel and the conductive bus is disposed within the cavity. (Original) The tubular garment of claim 14, wherein the at least one conductive yarn is disposed in the cavity.
 16. The tubular garment of claim 13, wherein the at least one conductive yarn is inlaid within the first fabric panel.
 17. The tubular garment of claim 13, wherein the conductive bus is electrically coupled to the at least one conductive yarn at one or more locations on the surface of the first fabric panel.
 18. The tubular garment of claim 13, wherein at least a portion of the at least one conductive yarn is disposed between non-conductive yarns of the first fabric panel.
 19. The tubular garment of claim 13, wherein the at least one conductive yarn is arranged within the tubular garment to provide resistive joule heating.
 20. The tubular garment of claim 13, wherein the first tubular portion defines an opening for fitting a limb of a wearer of the tubular garment. 